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I purchased an entire set of interior plastics from Vantage Plane Plastics. I got the show special at Sun-N-Fun. What a bargain! 50 interior parts that are each 1/4 inch too big in every dimension. I simply cannot get the right rear window trim to fit inside the opening. Notice how the aft headliner bows down in the center? Too big! There is really nothing one can do to make these parts fit better. They can be formed and bent with heat, but not shrunk. Cutting each part into 4 pieces with a band saw and gluing them back together would come close, but, of course, it would look like junk. I am using #8 machine screws throughout the interior to hold the panels up. The clip nut in the pic is far superior to the aluminum tab/sheet metal screws Cessna used. I am doing my best to avoid those sheet metal screws wherever possible
It truly takes about 1 day per large interior part to fit it properly. I suspect three weeks work in total to finish the plastic. Not easy, and I have 10 years interior experience.
Notice the AV-30 on the stringer? it has remarkable penetration, This particular seam is also an outside skin overlap. The AV-30 clearly found it’s way to the outside edge and beyond. So far, I have been able to locate almost every screw with enough accuracy.
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